It seems that Ford uses the temperature at the IAT sensor (
intake air sensor) to decide charging rate, slow charge rate when hot out and faster when cold out.
The generator does not output (not commanded to) until after the engine is running, so just "key on" will not put the grey or blue wire into a voltage state worth checking.
Unfortunately, it doesn't give any more insight. If the cables are good, the 10a fuse is good, you have voltage at the red wire that's equal to battery voltage reading, the ground is good....it just says replace the generator.
The alternator is internally regulated, but it gets it's working orders from the Computer Module based on the voltage and air temperature at the IAT sensor.
Try looking for and changing the IAT sensor. I don't know if that will work...but it's the only solution I found.
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